EVALUATION 

PARTICULATE/HF/HC1 EMISSIONS TESTING 

ON THE 

SCRUBBER/BAGHOUSE EXHAUST 

OF 

TUNNEL KILN #1 

BORAL BRICKS, INC. 

AUGUSTA PLANT 4 

1630 ARTHERN ROAD 

Augusta(Richmond County), Georgia 30901 

Project # 02132 

October 17, 2002 

Testing conducted for: 

Mr. David lohnson 

Environmental Manager 

Boral Bricks, Inc. 

PO Box 1178 

Columbus, Georgia 31902 

(334) 480-2487 

ANALYTICAL TESTING CONSULTANTS, INC. 

301 Brookdale Street 

Kannapolis, N. C. 28083 

(704) 932-3193 phone 

(800) 733-3193 toll-free 

(704) 932-0570 fax 

corp @ atc-net.net e-mail 

www.atc-net.net Web page 

Distribution: 

Mr. David Johnson 

(Three copies) 

Issue Date: 

November 14, 2002 
INTRODUCTION 

This report presents the results of particulate/hydrogen fluoride/hydrogen chloride emissions 

testing conducted on the scrubber/baghouse exhaust of the Plant 4 #1 Tunnel Kiln. Evaluation 

emissions testing via US EPA methods 5/26a was performed by Analytical Testing Consultants, 

Inc. of Kannapolis, NC. The two man test team consisted of Dan McCombs and Kevin Adkins. 

Testing was completed on Thursday, October 17, 2002. Mr. David Johnson of BoralBricks was 

on site during sampling and was responsible for collection of process data. Two separate runs 

approximately one-hour in duration were conducted. Changes to the operation parameters of the 

dry lime scrubber and the pressure drop across the baghouse where made for the two runs labeled 

seven and eight evaluation. 

Executive Summary 

Both runs showed the HF and HC1 emissions were well below levels contained in facility Part 70 

operating permit (3251-245-0009-V-01-5) of 2.25 lbs per hour. Runs 7 and 8 averaged 0.444 

lbs/hr particulate, <0.008 lbs/hr HF and 0.052 Ibs/hr HC1. Allowable particulate emissions (are 

based upon total quantities from the Clay Feed System Conveyor Belts, Surge Bins, and the 

Tunnel Kiln #1 [Rule 391-3-1-.02(2)(e)]. 

CERTIFICATION OF RESULTS 

"By our signature we certify that the testing and the reporting of the test results contained herein are prepared to 

the best of our abilities and that, to our knowledge, the data have been calculated and reported correctly. No data 

or information has knowingly been omitted." 

W. Keith Poole 

Laboratory Manager/Technical Director 

C. Daniel McCombs 

Quality Manager/Team Leader 

Page 3 of 78 
RESULTS SUMMARY 

SYSTEM Boral Bricks 

Tunnel Kiln #1 

TEST DATE 10/17/02 

PARAMETER Run #4 Run #5 Run #6 

GENERAL 

QS, FLOW, ACFM 48579 49056 47265 

Q STD DRY., FLOW SCFM 36802 37304 35847 

Vm STD (ft3) 39.49 40.57 38.58 

%1 100.50 101.88 100.82 

PARTICULATE EMISSIONS 

PMRc (Ibs/hr) 0.222 

Cs (GR/SCFD) 0.0007 

HYDROGEN FLOURIDE EMISSIONS 

PMRc (Ibs/hr) <0.007 

Allowable (Ibs/hr) 

HYDROGEN CHLORIDE EMISSIONS 

PMRc (Ibs/hr) 0,041 

Allowable (Ibs/hr) 

0.426 

0.0013 

<0.006 

0.030 

0.467 

0.0015 

<0.007 

0.044 

AVERAGE 

.48300 

36651 

0.372 

0.0012 

<0.007 

2.25 

0.038 

2.25 

Page 6 of 202 
SYSTEM 

TEST DATE 

PARAMETER 

GENERAL 

QS, FLOW, ACFM 

Q STD DRY, FLOWSCFM 

Vm STD (ft3) 

%1 

PARTICULATE EMISSIONS 

RESULTS SUMMARY 

Boral Brick 

Tunnel Kiln # 1 

10/17/02 

R #7E R #8E 

49731 49504 

37510 37164 

40.33 30.10 

100.71 101.16 

PMRc (Ibs/hr) "0.431 0.457 

Cs (GR/SCFD) 0.0013 0.0014 

HF EMISSIONS 

PMRc (Ibs/hr) <.006 <.009 

HCI EMISSIONS 

PMRc (Ibs/hr) 0.036 0.069 

A VERA GE 

49617 

37337 

0.444 

0.0014 

<0.008 

0.052 

Page 5 of 78 
SAMPLING AND ANALYTICAL PROCEDURES 

Particulate/HC1/HF emissions testing and analysis were performed according to procedures 

developed bY the U. S. Environmental Protection Agency (USEPA) and referred to as Method 

5/26A. Sampling port locations and number of test points to be used were determined according 

to Method 1 and are shown in the data sheets section of this report. The above federal test 

methods appear in the Code of Federal Regulations (Reference 1). 

Test point locations and sampling port placement for velocity traverses are shown in the data 

sheets. Test point locations were calculated based upon a 59.25" diameter, round stack with 2 

four inch test ports located ninety degrees apart. 

Twelve points were sampled in each test port. An all glass US EPA method 5/26a sampling train 

was utilized that employed glass nozzles and probe liners. A glass filter assembly held a Teflon 

filter frit with Teflon filter for determination of particulate emissions. Connections to the 

condenser train was a glass "double el" with a thermocouple well for measurement of exhaust 

temperature ?f the filter. The condenser train consisted of five glass impingers connected 

sequentially. The first and second impingers were charged with 100 ml 0.1 N H2SO4, the third 

and fourth with 100 ml of 0.1 N H•_SO 4. The fifth impinger contained 300g of silica gel. All 

sample recovery was conducted on-site by Dan McCombs and Kevin Adkins. Condenser train 

collections were measured and rinsed into pre-labeled amber glass jars. The sulfuric acid 

fractions were forwarded to Enthalpy Analytical, Inc. a LELAP accredited laboratory (Certificate 

No. 04010, agency interest no. 85848). A copy of Enthalpy's accreditation is included in 

Appendix I. for determinations of HC1/HF via US EPA 26a. The sodium hydroxide fractions 

were discarded. 

The front half of the sampling train was rinsed with reagent grade acetone and stored in 500 ml 

Nalgene® bottles and transported to ATC for analysis. Liquid levels were marked on the 

sampling bottles with a marker. Particulate analysis was completed Analytical Testing 

Consultants, Inc., a LELAP accredited laboratory (Certificate No. 04044) 

A blank of the acetone reagent was collected in the field, along with the field samples and 

analyzed side by side. According to standard practices and the QA/QC handbook EPAo600/4-94- 

038c, acetone blanks should not be subtracted over 0.001%. The acetone residue of 0.0004 was 

well under the maximum allowable residue of 0.0008. Corrections are show in the particulate 

lab report. 

Page 7 of 78 
PARTICULATE EMISSION RATE CALCULATION 

LOCA T/ON: Boral Brick 

SOURCE: Kiln 

DATA R #7E R #8E AVERAGE 

DATE 10/17/02 10/17/02 

RUN TIME (min) 60.00 45.00 

Dn (in) 0.250 0.250 

An (ft2) 3.41E-04 3.41E-04 

AVG DH (in H20) 1.56 1.51 

P ATM (in Hg) 29.64 29.64 

Pm (in Hg) 29.75 29.75 

Ps (GAUGE) -0.54 -0.54 

Ps (IN HG) 29.60 29.60 

Tm (F) 100.13 84.44 

Tm (R) 559.80 544.11 

Vm (ft3) 41.58 30.17 

Vm STD (ft3) 40.33 30.10 

VLQ (ml) 34.70 29.00 

VV STD (ft3) 1.64 1.37 

V STD (ft3) 41.96 31.47 

%M 3.90 4.35 4,12 

MD 0.961 0.957 

MWD 28.94 28.94 

M 28.51 28.47 

Ts (F) 205.88 "205.89 205.88 

Ts (R) 665.55 665.56 665.55 

SUM SQRT DP 16.29 12.15. 

N DP 24.00 18.00 

A VG SQRT DP 0.68 0.68 

CP 0.84 0.84 

Vs (ft/s) 43.29 43.09 43.19 

Ds (in) 59.25 59.25 

As (ft2) 19.15 19.15 

QS, FLOW, ACFM "49731 -49504 49617 

Q STD (ft3/min) 39031 38853 38942 

QSTDDRY, FLOWSCFM 37510 "37164 37337 

WT(gm) 0.0035 0.0028 

%1 100.71 101.16 

%C02 1.00 1.00 1.00 

%02 19.42 19.51 19.47 

%C0 0.00 0.00 

%N2 79.58 79.49 

PMRc (Ibs/hr) 0.431 0,457 0,444 

Cs(GR/SCFD) 0.0013 0.0014 0.0014 

Page 10 of 78 
HCI EMISSION RATE CALCULATION 

LOCATION; Boral Brick 

SOURCE: Tunnel Kiln #1 

DATA R #7E R #8E 

DATE 10/17/02 10/17/02 

RUN TIME (min) 60.00 45,00 

Dn (in) 0.250 0.250 

An (ft2) 3.41 E-04 3,41E-04 

A VG DH (in H20) 1.56 1.51 

P A TM (in Hg) 29.64 29.64 

Pm (in Hg) 29.75 29.75 

Ps (GAUGE) -0.54 -0.54 

Ps (IN HG) 29.60 29.60 

Tm (F) 100.13 84.44 

Tm (R) 559.80 544.11 

Vm (ft3) 41.58 30.17 

Vm STD (ft3) 40.33 30.10 

VLQ (ml) 34.70 29.00 

VV STD (ft3) 1.64 1.37 

V STD (ft3) 41.96 31.47 

%M 3.90 4.35 

MD 0.961 0.957 

MWD 28.94 28.94 

M 28,51 28.47 

Ts (F) 205.88 205.89 

Ts (R) 665.55 665.56 

SUM SQRT DP 16.29 12.15 

N DP 24.00 18,00 

A VG $QRT DP 0.68 0.68 

CP 0.84 0.84 

Vs (ft/s) 43.29 43.09 

Ds (in) 59.25 59.25 

As(ft2) 19.15 19.15 

Q$, FLOW, ACFM 49731 49504 

Q STD (ft3/min) 39031 38853 

Q STD DRY, FLOW $CFM 37510 37164 

WT (gin) 2.9100Eo04 4.2200E-04 

%1 100.71 101.1 6 

%C02 1.00 1.00 

%02 19.42 19.51 

%C0 0.00 0.00 

%N2 79.58 79.49 

PMRc (Ibs/hr) 0.036 0.069 

Cs (GR/SCFD) 0.00011 0.00022 

AVERAGE 

4.12 

205.88 

665.55 

43,19 

49617 

38942 

37337 

1.00 

19.47 

0.052 

0.00016 

Page 12 of 78 
ISOKINETIC DATA AND CALCULATIONS 

DATE 

SOURCE 

R #8E 

POINT # 

A1 

A2 

A3 

A4 

A5 

A6 

A7 

A8 

A9 

AIO 

All 

A12 

B1 

B2 

B3 

B4 

B5 

B6 

10/17/O2 

Kiln 

Tm 

K= 3.311 

Ts dp dH SQRT DP 

83 205 0.470 1.56 0.686 

84 206 0.410 1.36 0.640 

85 206 0.490 1.62 0.700 

85 207 0.490 1.62 0.700 

87 207 0.480 1.59 0.693 

87 208 0.460 1.52 0.678 

87 207 0.460 1.52 0.678 

86 207 0.450 1.49 0.671 

85 206 0.430 1.42 0.656 

86 205 0.430 1.42 0.656 

85 203 0.440 1.46 0.663 

85 202 0.420 1.39 0.648 

84 204 0.450 1.49 0.671 

83 206 0.460 1.52 0.678 

83 206 0.450 1.49 0.671 

82 207 0.470 1.56 0.686 

82 207 0.480 1.59 0,693 

81 207 0.470 ,1.56 0.686 

%02 

19.5 

19.6 

19.6 

19.7 

19.5 

19,4 

19.3 

19.5 

19.6 

19.6 

% C02 

84.44 

Vm(ft3) 

205.89 

Initial 406.39 

Final 436.56 

Total 30.17 

1.51 1•153 1•53 

correctedper6C-1 1•51 

% N2(BYDIFFERENCE• 

%Excess A• 

Calibration Actual 

Gas 

Zero 0.0 

Mid-Ranc•e 10.6 

Hi-Ranae 19,0 

Calibration Data 

Instrument Reading 

Pre- -Post Pre0.2 0.2 0.95 

10.7 10.7 0.48 

n/a n/a n/a 

Based upon 2% of span value (21%) 

% Error* 

1.00 

79.49 

1327.32 

-Post 

0.95 

0.48 

n/a 

Page 14 of 78 
ISOKINETIC SAMPLING RATE CALCULATION 

dH KdP 

K (846.72*Dn^4*dH @*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm) 

R #7E R #8E 

Dn 0.250 0.250 

dH@ 1.87 1.87 

Y, gamma factor 1.03 1.03 

Cp 0.84 0.84 

Bw(FRACTION, NOT%) 0.05 0.05 

Md 29.00 29.00 

Pbar 29.64 29.64 

PS (GAUGE) -0.54 -0.54 

Ps 29.60 29.60 

Tin, F 100.00 90.00 

Tm, R 559.67 549.67 

Ms 28.45 28.45 

Ts, F 205.00 205.00 

Ts, R 664.67 664.67 

Pm 29.75 29.75 

Page 16 of 78